Apex International, a global provider in anilox and embossing technologies, hosted a Repro Supplier Meet on 26 July 2023 at its plant located in Sinnar, Nashik. The one-day event, which was well attended by leading repro and plate suppliers across India, was dedicated to highlighting the challenges faced by repro houses concerning anilox technology.
Mangesh Bhise, director of sales, Asia Pacific and ME, emphasized the importance of the event. “In light of the current and future trends in flexography, it has become increasingly evident that a high level of integrity is required among key stakeholders/components in the flexo ecosystem.” The event provided scientific facts related to the manufacture and measurement of Anilox engraving, the pros and cons of ECG v/s CG (CMYK), and the opportunities in the flexo industry if suppliers unite.
Flexography, as a printing process, relies on a multitude of variables where design, repro, and anilox play a vital role in providing the desired output. This event was designed to demonstrate how the anilox capabilities influence the flexo process and, therefore, did not focus on plate and ink specialty surface patterns or pigmentation.
Nick Harvey, technical director, highlighted the importance of anilox roll in mastering quality print production. “The Anilox is a very technical product, which, if not controlled, will result in Anilox that can be measured as the same values on LPI or Lpcm and volume but could deliver different amounts of ink transfer and color. In addition to cell geometry, the same LPI or Lpcm with hexagonal cells can be manufactured with different volumes and different cell shapes. Whereas GTT 2.0, our patented open Slalom ink channel geometry, is always produced to have the optimum opening to depth ratio,” he emphasized.
Apex’s live demonstration
To demonstrate the consistency of GTT, Apex International included a live volume measurement demonstration. Three different GTT anilox were measured with MicroDynamics 3DQC (industry premier device).
The result proved that the channel shape, size, finish, and volume are extremely consistent, measuring at 4.21 cm3/m2, 4.24 cm3/ m2, and 4.28 cm3. “This level of consistency is a key USP of GTT. To be able to achieve this level of repeatability in the engraving gives the flexo process a firm foundation to build on, which will result in faster changeovers, less waste, higher quality imagery and enable ECG or CG to be adopted easier,” Harvey said.
Consistent engraving delivers consistent and predictable ink density. To demonstrate this, Harvey performed live printing using three GTT C3.5 anilox using the same unit, plate, and ink. To push the demonstration to the limit, black color – the most challenging of CMYK – was used for printing. The density achieved across the three samples was 1.29, 1.26, and 1.35.
Harvey said, “As stated earlier, this test was not to showcase any plate, plate screening, or ink. We are fully aware that the required ink density for black should be around 1.45 to 1.6, However, to prove consistency, this test demonstrated a perfect example of benefits from the GTT engraving.”
According to Harvey, printers may have many sets of conventional anilox that you can test in the same way to evaluate the anilox performance. It is also important to acknowledge that the anilox is the foundation and not the single solution for the process of printing to be in control.
Acknowledging the ever-evolving print industry landscape, Harvey discussed the rising popularity of digital print due to shorter runs and personalization. He asserted that flexo has a unique edge in the form of embellishments, with textures and 3D effects that can attract customers and open new markets for label printers. “By adopting CMYK. a printer can achieve 835 Pantone colors. This has not yet been achieved sufficiently. Printers can cater to high-value products and markets by utilizing remaining print stations for label and packaging embellishment.”
Harvey demonstrated the use of matt, gloss, and tactile lacquers to produce raised effects, paper feel effects, and 3D effects whilst using the standard flexo units inline. The event ended by emphasizing how key suppliers to the flexo industry evolve and work together to provide its joint customers.
